The plant is divided into 2 similar and independent macro stations, one for the production of the inner rings and one for the outer rings.
The single macro station consists of:
Siemens 840D SL CN
Control parameters unit (verification and storage of process variables in real time)
Entry conveyor
Washing system
Vision system for recognition the code and the serial number of the rings
ABB robots for moving pieces between stations/conveyors
Rotating table MF/HF hardening processes (3 different processes in parallel)
Rotating table tempering process
Exit conveyor
Scrap conveyors (differentiated for each phase of work)
Rings diameter: from 150mm to 320mm (Outer ring) / from 110mm to 250mm (Inner ring)
4-STATION VERTICAL HARDENING MACHINE FOR TRANSMISSION SHAFTS WITH AUTOMATIC LOADING AND UNLOADING BY ROBOT
The plant consists of the following macroblocks:
Hardening machine: induction hardening vertical machine with 4 stations, equipped with 2 induction heating generators. Each one has an output power of 300kW. They are able to work even individually, on a reduced cycle, to meet any production drops. The lunettes allow to limit the axial deformation of the shafts. The system control, entrusted to the CN Siemens 840D SL, and the specially designed mechanics, allow to treat different diameters without having to change any mechanical equipment. The same inductor is used for all types of shafts.
Measurement station: it aims to verify that the input shafts correspond to those loaded in the recipe of the CNC. Control takes place on the length, diameters and positioning of the groove. The system singularizes and positions the shafts to the distance required by the Robot clamps.
Robot: the robot, equipped with double gripper, picks the shafts from the measuring station and places them in the machine between the tailstocks, then it picks up the hardened shafts and deposits them, depending on the case, on the exit conveyor, in the quality control station or in the rejects area.
Other: drawer for quality control, cooling system for quenching liquid with tank, filter and pumps, guards and barriers equipped with interlocked closures and Parameter Control Unit.
4 STATION VERTICAL HARDENING MACHINE
Installation for vertical hardening and tempering by induction process.
It is able to automatically perform hardening / tempering treatments of flanged shafts, semi-axles, bars with 4 treatment stations.
The plant is totally built on a base with an electro-welded steel structure.
All the panels, pipes and the quench tank are made of stainless steel.
Electrical CNC components and operator panel by SIEMENS.
Integrated treatment Parameter Control System.
Teleservice for assistance and remote support.
INSTALLATION FOR HARDENING AND TEMPERING OF BEARINGS
Automatic machine for hardening and tempering of different types of bearings with different diameters.
The system is able to treat Inner Ring, Outer Ring, Hub of different diameters and thicknesses.
The loading / unloading conveyor allows the installation of the system in-line, where high production is required.
It is installed a final washing / drying station with dedicated liquid.
The plant is totally built on a base with an electro-welded steel structure.
All the panels, pipes and the quench tank are made of stainless steel.
Electrical CNC components and operator panel by SIEMENS.
Integrated treatment Parameter Control System.
Teleservice for assistance and remote support.
ATEX 2014/34 / EU CERTIFIED PLANT FOR STACK ISOLATION BY EPOXY RESIN APPLIED WITH SPRAY COATING TECHNOLOGY
Safety equipment:
Explosion suppression device with Sodium Bicarbonate (SBC)
Inerting system for the resin spraying booths according to the UNI EN 1127-1
Armature dimensional range:
Lamina stack diameter: from 19.0 to 50.0 mm
Lamina stack length: from 15.0 to 45 mm
Shaft diameter: 4.0 to 8.0 mm
Technological flow:
Taking the armature from the production line
Transport to the loading position on the resin coating machine
Lamina stack length control
Load armature on resin coating equipment
Armature induction heating
Introduction of the armature in the spray booth; application with spray coating method of the resin and curing of the film
Discharge armature on conveyor towards post curing station of the resin film
Armature cooling
Unloading the isolated armature on the pallet of the production line
Performances:
7.5 sec / piece for lamina stack Ø 45.0 mm stack length from 19 to 45 mm
6.0 sec / piece for lamina stack Ø 24.0 mm stack length 40 mm
DESIGN AND CONSTRUCTION OF MACHINERY:
HEATING ELECTRIC MOTOR CASING AND FITTING OF STATOR
HEATING ELECTRIC MOTOR ROTOR FOR MOTOR SHAFT INSERTION
Termomacchine designs and manufactures systems for hot assembly of the stator and rotor shaft of electrical motors specifically developed for electric cars.
Motors with high performance that require large mounting accuracy and low heating temperatures not to affect the mechanical properties of the materials used.
The IGBT generators consist of an electrical cabinet and a heating head on which the load adapter is installed. In some applications the insulation towards the grid is obtained by adding a three-phase 50 Hz transformer to the generator power supply. The operator panel is easy to use, with indications of the machine load, energy, heating times and power.
It is possible to insert frequency switches with pneumatic control and / or power switches to use the same generator for alternate heating with two independent heating heads
In addition to installation on current systems, they are easily adaptable for retrofitting old systems.
Parallel oscillating circuit
MOSFET Generators are usually composed of a cabinet and a heating head. The insulation towards the network is obtained by placing a three-phase 50 Hz transformer placed before the generator.
AVAILABLE SIZES:
Frequency band 50-250 kHz up to 150Kw
Powers above 500kW with frequencies up to 350kHz are obtained using a heating head for welding machine
COMPACT GENERATORS SIZES:
Frequency range 20-100 kHz with IGBT and power of 25-50Kw
Frequency range 50-250 kHz with MOS and power of 25-50Kw
DESIGN AND MANUFACTURING OF INDUCTORS FOR HARDENING AND TEMPERING, INDUCTORS DESIGN FOR VARIOUS INDUCTION HEATING APPLICATIONS
Termomacchine designs and manufactures inductors specifically developed to perform hardening and surface tempering of mechanical components subject to wear and mechanical stress during operation for the automotive sector, OIL & GAS, and plant engineering.
Furthermore, Termomacchine designs and manufactures specific inductors for other applications including hardening (low thickness automotive components), forging, braze welding, heat shrinking and curing of protective coatings on cables or rotors of electric motors.
The design of the tempering inductors is based on a practical and theoretical knowledge of all the phenomena that involve the heating and the induction of hardened steels that can be conducted at very high temperatures in a short time and in a deliberately localized way: in particular on the surfaces of mechanical components to which is requested to withstand specific mechanical stresses and / or superficial wear during operation.
The first draft of the project is performed on a 3D CAD according to the experience of a team made up of designers, builders, and metallurgists. The prototype realized can be tested and modified in several phases until the target set by the customer is reached.
The final design is fixed in order to ensure the repeatability of the process in case of replacement or repair due to wear of the inductor component. Where necessary, specific equipment is designed and produced that allow precise assembly and off-machine setup of the inductors: the possibility of verifying conformity with their geometry in a simple and intuitive way is always guaranteed.
The deep knowledge of the materials used in the construction, their targeted application, the great experience in the practical realization and the testing are the foundations of the inductors development in Termomacchine.
The iter described above is followed in each application for which it is necessary to reach hardening temperatures, forging, braze welding, keying of mechanical components and application of protective coatings, if the geometry of the system does not fit between previously studied applications.
Termomacchine Working team may offer original spare parts and accessories covering range of machines we produce.
Starting from design, to engineering, and building, all activities are made in house.
TM can count on an engineering dept able to design and conceive new equipment solutions with dedicated tooling at new generation standard.
Ranging from mechanics, to process setup, to coil design and matching transformers, to the HW & SW high level engineering, till to found building and manufacturing of projects in our workshop, highly skilled and able to give shape to projects on time and manners allowing us to meet our Clients requirement and expectations.
Supported by an innovative Metallurgic Laboratory ready for trails and treatment process set up to meet specs more and more strict.
An Electronic Laboratory operating in synergy with R&D to finalize innovative solutions for our IGBT & MOSFET generators.
Able to produce, test and calibrate the totality of our own made electronic boards 100% in house.
Laboratories and Workshops are allowing us to offer spare parts and repairs of all TM designed parts.
Very fast manufacturing time and availability of spares on stock are our target.
After Sales Team is always ready for you and responding on time, capable to propose tailored solutions and lead time more and more fast.
The new model of Termomacchine induction welding machine is available from 150kW up to 800kW in a very compact chassis (L.1700xH.850xW650). Compared to the previous model, accessibility in case of maintenance has been further improved. The internal lay-out and the electronics are also already designed for the implementation of the new power boards with SIC technology.
Even the cooling system has been completely redesigned, allowing the removal of the air conditioner on the top of the chassis with the advantage of reliability and efficiency.
An electromechanical frequency switch system is available as an option to guarantee maximum efficiency even with a transition from Austenitic o Ferritic Inox steel welding process or in case of an un-optimized inductor / impeder.
The new SIC semiconductor power boards will guarantee a further gain in terms of efficiency and performance, with frequencies above 500kHz.
ATEX 2014/34 / EU CERTIFIED INDUCTION TURN KEY INSTALLATION FOR ON-LINE SOLUBILIZATION OF AUSTENITHIC, DUPLEX, SUPERDUPLEX, FERRITIC STAINLESS STEEL TUBES
The heat treatment of solubilization, also known as bright annealing, consists in a phase of heating and maintenance of the high tube temperature followed by a rapid cooling, aimed at bringing back into solution the precipitates of chromium carbides, which are typically responsible for corrosion inter-crystalline.
At all phases of heat treatment, a highly reducing gas atmosphere is required, since hydrogen is the commonly used gas.
Dimensional range of tubes: from 10.0 x 0.5 mm to 30.0 x 2.0 mm
Material: stainless steel AISI 304 AND 316 L
Gas atmosphere: from 20% to 100% of H2 gas depending on the required metallurgical characteristics
Performances:
AISI 304 L pipe Ø 26.0 x 1.05 mm
Line speed 22 m / min. equal to 850 Kg / H
AISI 304L pipe Ø 30.0 x 1.05 mm
Line speed 19 m / min. equal to 840 Kg / H
INSTALLATION FOR IN-LINE BRAZING OF DOUBLE-WALL STEEL TUBES FOR CIRCULATION OF FUEL AND BRAKE FLUID
Double-wall steel pipes represent the economic alternative to seamless pipes; they have many of the same qualities as seamless tubes and are suitable for most high-pressure applications.
This brazed double-wall steel tube is produced according to SAE J527 and ASTM A254 specifications and meets the standards of the automotive industry.
The double-wall steel tubes are made from steel strips coated with copper or nickel-plated copper and rolled to produce a double-walled tube which is then brazed in a controlled atmosphere.
The brazing of copper produces a continuous bond between the steel layers creating a tube with a high burst strength and fatigue resistance of the vibrations.
Performances:
Double walled copper / copper steel pipe
Tube diameter: 4.76 or 6.35 mm
Brazing speed: 80 m / min.
IN-LINE STESS RELIEVING INSTALLATION OF LOW CARBON SINGLE WALL STEEL TUBES
The small diameter single wall tube is widely used in the automotive, refrigeration, air conditioning and heat exchangers sectors.
The single wall tube production process requires a Stress relieving heat treatment before the tube is coated with anti-corrosion coating like: Zinc, Galfan, Pvf, Nylon, Epoxy, or Nickel.
Treatment temperatures range between 730 ° C to 850 ° C (gasoline transport tube).
After heating, the tube cools by passing through a tunnel in a protected atmosphere.
Composition of the installation:
One or two High-Frequency Generator Fully Solid State Termomacchine
An inductor bech with a total length of 2 meters
Group of control and distribution of the protective atmosphere
Tube cooling tunnel: length up to 106 m
Performances:
Tube diameter: from 4.76 to 12.7 mm
Achievable speeds:
Ø 4.76 mm: 250 m/min
Ø 6.0 mm: 189 m/min
Ø 6.35 mm: 177 m/min
Ø 8.0 mm: 137 m/min
Ø 9.5 mm: 113 m/min
Ø 10.0 mm: 108 m/min
Ø 12.7 mm: 85 m/min
INSTALLATION FOR HOT FORMING OF BUTT WELDING ELBOWS
The unique design of the inductor heating improves efficiency and allows substantial energy savings.
The tilting induction coil simplifies and speeds up the set-up of the press.
Machine composition:
Medium frequency converter Fully Solid State Termomacchine power from 200 kW to 1,000 kW
Water / water cooling system for generator cooling and inductor bench
Single or multiple heating inductor (process from 2 to 5 tubes per cycle)
Biaxial mechanical device for adjusting the heating inductor position
Inductor tilting group
Performances, by way of example:
Pipe section diameter: 88.9 mm w.t. 5.6 mm - L = 535 mm
Number of spindles: 3
Treatment temperature: 1,000 ° C
Cycle / h: 16
Frequently the end Customer requires consumables kits for the first 6/12 months of production or to perform the performance tests. Termomacchine cooperates with USM Mazzucchelli Srl to provide a wide range of inductors, impeder, ferrites and fiberglass tubes to complete the supply of induction welders.
Frequently the end Customer requires consumables kits for the first 6/12 months of production or to perform the performance tests. Termomacchine cooperates with USM Mazzucchelli Srl to provide a wide range of inductors, impeder, ferrites and fiberglass tubes to complete the supply of induction welders.
Frequently the end Customer requires consumables kits for the first 6/12 months of production or to perform the performance tests. Termomacchine cooperates with USM Mazzucchelli Srl to provide a wide range of inductors, impeder, ferrites and fiberglass tubes to complete the supply of induction welders.
DESIGN AND MANUFACTURING INDUCTORS FOR TUBE WELDING, TUBE ANNEALING, DOUBLE WALL CLUTCH WELDING, BRIGHT ANNEALING OF STAINLESS-STEEL TUBE
Termomacchine designs and manufactures inductors specifically developed for the production, in particular:
The design of the inductors for tube applications starts in accordance to the previous applications and it is developed following data of the efficiency of the welding system in terms of energy used according to the required productivity.
If a new study is required, specific tests are carried out on prototypes and impedance measurements: this allow to foresee a precise sizing of the inductor and of the heating system.